LEAN MAINTENANCE MANAGEMENT

1-COURSE OVERVIEW:-
Maintenance shares significant operating costs in an organization.
It is considered as a main pillar of the organizational performance.
Lean thinking can be incorporated into maintenance activities
through applying its principles and practices.
the goals are improving productivity and reducing cost by
maximizing the effectiveness of all machines, facilities and processes
employed through the reduction or prevention of breakdowns by
collectively, revitalizing machines, and by stopping unnecessary
repairs. Lean Maintenance also increases the effectiveness of all
employees through joint decision making & shared responsibility
through their meaningful involvement.
Part of the program shall tackle Autonomous Maintenance to
identify & correct abnormalities, which can lead to downtime &
tagging the abnormalities

2 – OBJECTIVE :-
This course will provide basic knowledge on the following:-
 Understand the concepts of costs, capital, profit and ROI
 Understand the cost impact of unanticipated failure
 Apply proactive policies to reduce future maintenance costs
 Structure and analyse failure data to reduce repetitive failures
 Identify root causes of unanticipated failure costs
 Reduce resource costs through efficient work management practices
 Decide rationally what maintenance activities to outsource and what
not
 Use the features, functions and benefits of lean maintenance
contracts

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  Use the most applicable type of maintenance contracts (incl. Service
Level Agreements) and when/how to apply them
 Define service levels and monitor the contractor performance
 Develop and negotiate a maintenance contract
 Recognize the pitfalls
 Evaluate the delivered performance of all parties involved
 Implement maintenance contract management

2 - THE SCIENTIFIC CONTENT OF THE PROGRAM: -

 Lean Introduction.
 Maintenance vision and mission.
 Maintenance policies.
 Breakdown deployment.
 ABC classification.
 Maintenance KPI's.
 Skill Matrix.
 Build up maintenance information System.
 Spare parts management system design and implementation.
 Maintenance daily meeting.
 Define predictive maintenance technologies.
 Assess the planned maintenance system cost and performance and
reconsider the priorities.
 5 Why, 4 M.
 Work order cycle and kind of work orders.
 Action plan.
 Case Study & implementations.

3- WHO SHOULD ATTEND :-

 Planners.
 Supervisors.
 Engineers.
 Reliability engineers.

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 Maintenance team leaders and managers.
 Operations team leaders and managers.
 Shutdowns and Turnarounds
 Engineering
 Reliability
 Asset Management
 Teams who have been assigned the responsibility of
establishing a maintenance contract will find it extremely
useful to attend this course as a unit.
 Anyone who wishes to update themselves on Maintenance
Contracts & Outsourcing

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 TOTAL QUALITY MANAGEMENT &
WORLD CLASS EXCELLENCE
ORGANIZATION
1-COURSE OVERVIEW:-
With the ever-increasing numbers of organizations pursuing quality
management, new applications and insights emerge frequently. This
course aims at providing participants with the latest knowledge
regarding Quality Management, along with practical
implementation tips. During this course; participants will have the
opportunity to participate in a number of short activities through
which they can explore the ideas, tools, and processes of total
quality management.
2 – OBJECTIVE :-
This course will provide basic knowledge on the following:-
 Awareness of Total Quality Management.
 Understand their quality roles and the impact of their functions on
quality.
 Understand Excellence Models& Awards.
 Criteria for Excellence Organization.
 Understand the Total Quality Management processes.
 Understand Quality Theories.
 Understand the basic quality improvement tools.
 Understand Process Control & develop suitable KPI’s
 Understand the effects of variation on processes and be able to use
that understanding to make sound decisions.
 Understand difference between (Lean, Six Sigma, Business Process
Reengineering, Theory of Constrain)
 Define Process Risks & develop Mitigation Plan

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2 - THE SCIENTIFIC CONTENT OF THE PROGRAM: -

 Quality Management & World Class Excellence Organization

Overview:
 Excellence Models.
 Operational Excellence.
 Six Sigma.
 Lean Enterprise/Kaizen.
 Business Process Reengineering.
 Theory of Constrains.
 Quality definitions.
 Customers & Customer satisfaction.
 Quality Costs.
 Cost of Poor Quality “COPQ”.
 Quality Processes.
 Quality Improvement.
 Quality Planning.
 Quality Control.
 Quality Foundations.
 Change Management.
 Quality Theories.
 Kaizen & 7 Basic Quality Tools.
 7 type of wastes.
 PDCA Cycle.
 Failure Mode and Effect Analysis – FM.EA.
 SIPOC Diagram.
 Process Flowchart.
 Data Collection tools.
 Kpis’s.
 Control Plans.

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  Case Study & implementations.

3- WHO SHOULD ATTEND :-

 Quality Supervisors.
 Quality managers.
 Individuals requiring a working knowledge and understanding
of total quality management (TQM).
 New and experienced candidates in quality who want to use the
TQM framework and proven approaches and tools to be more
effective on the job.
 Quality professionals and management representatives.

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 KAIZEN FOR PROCESS INNOVATION
AND IMPROVEMENT
1-COURSE OVERVIEW:-
Excellent organizations continuously learn, both from their own
activities and performance and from others. They rigorously
benchmark, both internally and externally. They capture and share
the knowledge of their people in order to maximize learning across
and within the organization. There is an openness to accept and use
ideas from all stakeholders. People are encouraged to look beyond
today and today’s capabilities. They are careful to guard their
intellectual property and to exploit it for commercial gain, where
appropriate. Their people constantly challenge the status quo and
seek opportunities for continuous innovation and improvement that
add value.
Course is designed to fulfil needs of improvement professionals to
achieve best process performance results using Kaizen tools. The
course shall provide in-depth know-how on have to using Kaizen in
order to improve a process.
Course provides hands on experiences on Kaizen tools
implementation with case studies & real projects examples
implemented in several industries.
2 – OBJECTIVE :-
This course will provide basic knowledge on the following:-
 Understand & Develop Mechanism for continuous improvement
and innovation using Kazien.
 Develop skills, knowledge and attitudes to continuous process and
product improvements.

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  Implement and apply full process of Kaizen.
 Understand and apply Kaizen tools for Process Innovation and
Improvement
 Understand role leadership & team in Kazien project.

2 - THE SCIENTIFIC CONTENT OF THE PROGRAM: -

 Operational Excellence.
 Introduction to Innovation and Process Improvement.
 Developing and implementing changes and improvements.
 Problem identification and analysis.
 Change in the external and internal environments.
 Motivation and morale.
 Gemba Gembutsu.
 Way to identify wastes.
 Kaizen Projects.
 Value chain analysis.
 Kaizen project implementation follow up.
 Idea Management Process.
 Opportunity search.
 Spaghetti Diagram.
 Idea generation for innovation.
 Case Study & implementations.

3- WHO SHOULD ATTEND :-

 Anyone who is willing to become continuous improvement

practitioner.
 This course is applicable in all types of industries at all levels.
 Healthcare Professionals who are new to kaizen as a method
for daily continuous improvement
 Managers.
 Process Owners.
 Project Team Members

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 Supervisors.
 Operations.
 Professionals who wish to clearly understand the Kaizen
philosophy and associated tools and techniques to improve
process performance.